Six Sigma Green Belt Certification Practice Exam

A Six Sigma improvement project has reduced the risk associated with a specific part of a production process. How can the next highest priority risk be found?

1. Develop a control plan

2. Hold a brainstorming session

3. Perform a failure modes and effects analysis

4. Perform a measurement system capability re-analysis

The correct answer is: Perform a failure modes and effects analysis

Performing a failure modes and effects analysis (FMEA) is the most effective way to find the next highest priority risk in a process. FMEA is a systematic approach used to identify potential failure modes in a system, process, or product, assess their impact, and determine the likelihood of their occurrence. This analysis helps in prioritizing risks based on their severity, occurrence, and detectability by calculating a risk priority number (RPN). By conducting an FMEA, the team can focus on the most critical risks that need to be addressed next, thus fostering continuous improvement in the production process. While developing a control plan is important for maintaining improvements and ensuring sustained performance, it does not directly identify new risks. Brainstorming sessions can generate ideas, but they aren't sufficient on their own for systematically evaluating risks. Re-analyzing measurement system capability focuses on the reliability of data collection methods, rather than identifying new failure modes or risks within the process. Hence, FMEA provides the structured approach necessary to pinpoint and prioritize the next critical risks effectively.